Photochromic ophthalmic lens

ABSTRACT

A photochromic ophthalmic lens and a process for its preparation are disclosed. The lens comprise a substantially transparent substrate having a lenticular shape and, at least one film adhering to at least one surface of said substrate. The film contains a resinous blend of polycarbonate resin, and poycaprolactone and an effective amount of a photochromic dye selected from a group consisting of spiropyrans, spiroxazines, fulgides and fulgimides. In an additional embodiment the film contains a copoly(carbonate-lactone) block or random copolymer.

FIELD OF THE INVENTION

The invention relates to a photochromic ophthalmic lens and more particularly to a lens made primarily of a polymeric resin.

BACKGROUND OF THE INVENTION

Current commercial ophthalmic lenses are produced from glass, allylcarbonate thermoset (thermosetting polycarbonate) or thermoplastic aromatic polycarbonate. Their relatively low weight and durability make the later materials desirable for the manufacture of ophthalmic lenses. The use of thermoplastic aromatic polycarbonate in this market has been increasing annually mainly because glass and thermosetting polycarbonate are inferior to thermoplastic aromatic polycarbonate in terms of impact resistance. Thermoplastic aromatic polycarbonate is therefore rapidly replacing both of these materials.

While current thermoplastic aromatic polycarbonate can closely match the performance of glass and thermosetting polycarbonate in almost every aspect, its photochromic behavior falls short of expectations. The incorporation of photochromic dyes into a thermoplastic aromatic polycarbonate (herein "PC") matrix is problematic. First, photochromic dyes in an unmodified PC matrix show slow transition between the light and dark forms. This slow transition rate makes the photochromic material less competitive with the glass and allylcarbonate thermoset photochromic lenses, which are presently commercially available. Second, the glass transition temperature of PC is relatively high and photochromic dyes are thermally sensitive. Hence, during the injection molding process, there is a distinct possibility that the dyes will degrade and shift the color of the corresponding lenses to a more yellow tint. The resulting color is generally unacceptable to the optical lens industry.

These shortcomings of thermoplastic aromatic polycarbonate in terms of photochromicity are perceived as a hindrance to wider acceptance of the material in this industry. Therefore, workers in the field have been attempting to produce a viable and economical thermoplastic aromatic polycarbonate lens having photochromic properties.

Methods for producing plastic lenses are known. U.S. Pat. No. 5,496,641 disclosed a plastic lens, the structure of which included a substrate of a particular refractive index, a primer layer comprising a metal compound, a hard coating layer and an anti-reflection layer.

U.S. Pat. No. 5,531,940 disclosed a method which entails providing (a) a finished or semifinished plastic lens preform having a first convex surface that is spherical or aspherical in geometry, (b) a mold having a molding surface at least a portion of which has a profile substantially matching the convex surface of the preform and (c) an uncured resin having a low crosslinking density and forms a soft matrix upon curing. These are arranged such that the uncured resin is disposed between convex surface of the preform and the molding surface of the mold, the composite plastic lens is impregnated with a photochromic material. In an additional embodiment of the '940 patent, the method entails using as (c) a photochromic-additive-containing uncured resin. In a still additional embodiment, the '940 patent disclosed a second uncured resin having a relatively high crosslinking density, which forms a scratch resistant matrix upon curing. Also disclosed is the method where the first uncured resin that has a low crosslinking density includes a photochromic additive. Polycarbonate is among the preferred materials for making the lens preform. A related method has been disclosed in PCT WO 95/15845. Also, presently practiced technology for manufacturing photochromic PC ophthalmic lens entails first cleaning a molded lens and then attaching a polyurethane film to one of the lens surfaces. To the outside surface of the polyurethane film there is then applied a second film, such as polyester, which contains appropriate photochromic dyes to form a combination through a thermal treatment of the combination, the photochromic dye diffuses, or migrates from the second film into the polyurethane film. The second film is then removed and the polyurethane surface is hard-coated to produce the final product. The resulting, now photochromic, combination is then used to make a lens. The process is economically unattractive and is characterized by its relatively low yield. Moreover, certain lenses, such as bifocals and progressives, cannot currently be produced by this method. On the other hand, it is important to have the dye on the outside surface of the lens most efficient in terms of activating the photochromic dye and only minimum amounts of the dyes are required to produce this photochromic lens. Moreover, in contrast to the thermal degradation which is often the consequence of having the photochromic dyes dispersed in the bulk material, thermal instability is not an issue because the dyes are transferred to the lenses at a relative low temperature.

The relevant art also includes U.S. Pat. No. 3,567,605 that disclosed a series of pyran and chromene derivatives that have been reported to undergo color change on exposure to radiation. Also relevant are U.S. Pat. Nos. 5,451,344 and 5,552,090 that disclosed the photochromic naphthopyrans, which are useful in the present invention. The '090 document disclosed the utility of such compounds in the preparation of photochromic articles molded of any polymeric resins including thermoplastic polycarbonate resins. Also relevant is U.S. Pat. No. 4,064,195 that disclosed a molding composition containing polycarbonate (PC) and polycaprolactone polymer (PCL).

A key object of the present invention is to provide a film having photochromic properties suitable for the manufacture of photochromic lenses.

An additional object is to provide a method for making a photochromic lens using the inventive film.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is based on the photochromic reversibility of the PCL/PC composition, which is the subject of patent application, U.S. patent application Ser. No. 08/887,075 (Attorney Docket Number Mo-4683) filed Jul. 2, 1997, assigned to Bayer Corporation. Accordingly, a blend of PCL and PC was found to be suitable for the incorporation of photochromic dyes and which, in its photochromic form features a transition between light and dark forms at a rate which is competitive with current commercial photochromic glass lenses and with lenses based on thermosetting carbonate.

In accordance with the present invention, a photochromic film, the resinous components of which comprise thermoplastic aromatic polycarbonate, PCL and a suitable photochromic dye is placed into the cavity of an injection molding tool and a suitable thermoplastic resin is then injected on top of the film to form a lens.

The present invention relates to a lens comprising a film prepared from a composition containing polycarbonate resin, polycaprolactone and a photochromic compound. The film, which is transparent and features desirable photochromic kinetics, makes it suitable in the preparation of ophthalmic lenses in accordance with the invention. The strong and transparent film demonstrates rapid transition between dark and light upon the exposure to and removal from the radiation source.

The film suitable for the preparation of a lens in accordance with the present invention comprise (A) at least one resinous component which may be a homogeneous blend of polycarbonate resin and polycaproactone (PCL) or a copoly(carbonate-lactone) copolymer, and (B) at least one compound selected from a group consisting of benzopyrans, naphthopyrans, spirobenzopyrans, spironaphthopyrans, spirobenzoxazines spironaphthoxazines, fulgides and fulgimides.

In the embodiment wherein A is a blend, the composition contains about 1 to 50 mole percent of polycaprolactone (the indicated percents throughout the present text refer to percent relative to the total weight of resinous components and photochromic compounds) and a positive amount of the photochromic compound, the amount being sufficient to render the composition photochromic. More preferably, the composition contains about 5 to 50% of PCL, 95 to 50% of polycarbonate and about 0.01 to 1.0 parts, preferably 0.03 to 0.5 parts per hundred parts of resin (pphr) of the photochromic compound. Polycaprolactone in the context of the invention is a polymeric resin having a weight average molecular weight of up to about 250,000, preferably 25,000 to 150,000, most preferably 30,000 to 100,000, the molecular structure of which contains units conforming to ##STR1##

Suitable PCL are partially crystalline resins, which are commercially available, such as from Union Carbide under the name Tone Polymers P-767 and P-787. The PCL preferably has a reduced viscosity (measured with 0.2 g of polymer in 100 milliliter benzene at 30° C.) of about 0.1 to 1.5, more preferably about 0.5 to 0.9.

The PCL is linear polyester formed through the ring opening reaction of ε-caprolactone.

Aromatic polycarbonates within the scope of the present invention are homopolycarbonates, copolycarbonates, branched polycarbonate and mixtures thereof. The polycarbonates generally have a weight average molecular weight of 10,000 to 200,000, preferably 20,000 to 80,000 and their melt flow rate, per ASTM D-1238 at 300° C., is about 1 to about 85 g/10 min., preferably about 2 to 15 g/10 min. They may be prepared, for example, by the known diphasic interface process from a carbonic acid derivative such as phosgene and dihydroxy compounds by polycondensation (see German Offenlegungsschriften 2,063,050; 2,063,052; 1,570,703; 2,211,956; 2,211,957 and 2,248,817; French Patent 1,561,518; and the monograph H. Schnell, "Chemistry and Physics of Polycarbonates", Interscience Publishers, New York, N.Y., 1964, all incorporated herein by reference).

In the present context, dihydroxy compounds suitable for the preparation of the polycarbonates of the invention conform to the structural formulae (1) or (2). ##STR2## wherein

A denotes an alkylene group with 1 to 8 carbon atoms, an alkylidene group with 2 to 8 carbon atoms, a cycloalkylene group with 5 to 15 carbon atoms, a cycloalkylidene group with 5 to 15 carbon atoms, a carbonyl group, an oxygen atom, a sulfur atom, --SO--or --SO₂ -- or a radical conforming to ##STR3## e and g both denote the number 0 to 1; Z denotes F, Cl, Br or C₁ -C₄ -alkyl and if several Z radicals are substituents in one aryl radical, they may be identical or different from one another; d denotes an integer of from 0 to 4; and f denotes an integer of from 0 to 3.

Among the dihydroxy compounds useful in the practice of the invention are hydroquinone, resorcinol, bis-(hydroxyphenyl)-alkanes, bis-(hydroxyphenyl)-ethers, bis-(hydroxyphenyl)-ketones, bis-(hydroxyphenyl)-sulfoxides, bis-(hydroxyphenyl)-sulfides, bis-(hydroxyphenyl)-sulfones, 2,2,4-trimethylcyclohexyl-1,1-diphenol and α, α-bis-(hydroxyphenyl-diisopropylbenzenes, as well as their nuclear-alkylated compounds. These and further suitable aromatic dihydroxy compounds are described, for example, in U.S. Pat. Nos. 3,028,356; 2,999,835; 3,148,172; 2,991,273; 3,271,367; and 2,999,846, all incorporated herein by reference.

Further examples of suitable bisphenols are 2,2-bis-(4-hydroxy-phenyl)-propane (bisphenol A), 2,4-bis-(4-hydroxyphenyl)-2-methyl-butane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, ,α,α'-bis-(4-hydroxy-phenyl)-p-diisopropylbenzene, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3-chloro4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, 2,2-bis-(3,5-dimethyl4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfide, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfoxide, bis-(3,5-dimethyl4-hydroxyphenyl)-sulfone, dihydroxy-benzophenone, 2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-cyclohexane, α,α'-bis-(3,5-dimethyl-4-hydroxyphenyl)-p-diisopropylbenzene, 2,2,4-trimethyl cyclohexyl-1,1-diphenol and 4,4'-sulfonyl diphenol.

Examples of particularly preferred aromatic bisphenols are 2,2,-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl4-hydroxyphenyl)-propane, 2,2,4-trimethyl cyclohexyl-1,1-diphenol and 1,1-bis-(4-hydroxy-phenyl)-cyclohexane.

The most preferred bisphenol is 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A).

The polycarbonates of the invention may entail in their structure units derived from one or more of the suitable bisphenols.

An additional embodiment of the invention is represented by a composition wherein resinous components comprise copoly(carbonate-lactone) block or random copolymer. In this embodiment of the invention, the copolymer contains 1 to 50 mole percent of units conforming to ##STR4## The Preparation of Such Copolycarbonates is Well Known in the Art

Among the resins suitable in the practice of the invention are included phenolphthalein-based polycarbonates, copolycarbonates and terpolycarbonates such as are described in U.S. Pat. Nos. 3,036,036 and 4,210,741, both incorporated by reference herein.

The polycarbonates of the invention may also be branched by condensing therein small quantities, e.g., 0.05 to 2.0 mol % (relative to the bisphenols) of polyhydroxyl compounds.

Polycarbonates of this type have been described, for example, in German Offenlegungsschriften 1,570,533; 2,116,974 and 2,113,374; British Patents 885,442 and 1,079,821 and U.S. Pat. No. 3,544,514. The following are some examples of polyhydroxyl compounds which may be used for this purpose: phloroglucinol; 4,6dimethyl-2,4,6-tri-(4-hydroxy-phenyl)-heptane; 1,3,5-tri-(4-hydroxyphenyl)-benzene; 1,1,1-tri-(4-hydroxy-phenyl)-ethane; tri-(4-hydroxyphenyl)-phenylmethane; 2,2-bis-[4,4-(4,4'-dihydroxydiphenyl)]-cyclohexyl-propane; 2,4-bis-(4-hydroxy-1-isopropylidine)-phenol; 2,6-bis-(2'-dihydroxy-5'-methylbenzyl)4-methyl-phenol; 2,4dihydroxybenzoic acid; 2-(4-hydroxyphenyl)2-(2,4-dihydroxy-phenyl)-propane and 1,4-bis-(4,4'-dihydroxy-triphenylmethyl)-benzene. Some of the other polyfunctional compounds are 2,4-dihydroxybenzoic acid, trimesic acid, cyanuric chloride and 3,3-bis-(4-hydroxyphenyl)-2-oxo-2,3-dihydroindole.

In addition to the polycondensation process mentioned above, other processes for the preparation of the polycarbonates of the invention are polycondensation in a homogeneous phase and transesterification. The suitable processes are disclosed in the incorporated herein by reference U.S. Pat. Nos. 3,028,365; 2,999,846; 3,153,008; and 2,991,273.

The preferred process for the preparation of polycarbonates is the interfacial polycondensation process.

Other methods of synthesis in forming the polycarbonates of the invention such as disclosed in U.S. Pat. No. 3,912,688, incorporated herein by reference, may be used.

Suitable polycarbonate resins are available in commerce, for instance, Makrolon CD 2005, Makrolon FCR 2400, Makrolon 2600, Makrolon 2800 and Makrolon 3100, all of which are bisphenol based homopolycarbonate resins differing in terms of their respective molecular weights and characterized in that their melt flow indices (MFR) per ISTM D-1238 are about 60 to 85, 16.5 to 24, 13 to 16, 7.5 to 13.0 and 3.5 to 6.5 g/10 min., respectively. A branched polycarbonate such as Makrolon 1239 can also be used. These are products of Bayer Corporation, of Pittsburgh, Pa.

A polycarbonate resin suitable in the practice of the invention is known and its structure and methods of preparation have been disclosed, for example in U.S. Pat. Nos. 3,030,331; 3,169,121; 3,395,119; 3,729,447; 4,255,556; 4,260,731; 4,369,303 and 4,714,746 all of which are incorporated by reference herein.

The dyes suitable in the context of the invention are photochromic compounds selected from the group consisting of benzopyrans, naphthopyrans, spirobenzopyrans, spironaphthopyrans, spirobenzoxzines, spironaphthoxazines, fulgides and fulgimides. Such photochromic compounds have been reported in the literature including U.S. Pat. Nos. 4,826,977; 4,931,221; 5,106,998; 5,552,090; 5,628,935 and 5,565,147 (all incorporated herein by reference).

The color range of the naphthopyrans suitable in the present invention is 410 to 500 nm, thus they impart a yellow or orange coloration in their darkened state. In the faded, or bleached condition, the materials exhibit a colorless or pale coloration. The present invention may be used in a mixture or combined with suitable organic photochromic compounds, to obtain, after activation, the formation of neutral coloring such as green, brown and gray. Particularly useful for the purpose are photochromic compounds belonging to the group of naphthopyrans, spiro-indolino-oxazines and spiro-indolino pyrans which are known and are available in commerce. These have a high quantum efficiency for coloring, a good sensitivity and saturated optical density, and an acceptable bleach or fade rate. These compounds may be represented by the following graphic formulae IA1, IA2, and IA3 in which the letters a through n represent the sides of the naphthopyran rings, and the numbers represent the numbering of the ring atoms of the naphthopyrans: ##STR5##

In graphic formulae IA1, IA2, and IA3, the group represented by A is a substituted or un-substituted, five or six member heterocyclic ring fused to the g, i, or I side of the naphthopyran and is represented by the following graphic formulae IIA through IIF: ##STR6##

In graphic formulae IIA through IID, X may be an oxygen or a nitrogen atom, said nitrogen atom being substituted with hydrogen or a C₁ -C₄ alkyl. R₁ may be hydrogen, C₁ -C₆ alkyl, substituted or unsubstituted phenyl, carboxy, or C₁ -C₆ alkoxycarbonyl. Preferably, R₁ is hydrogen, C₁ -C₃ alkyl, substituted or unsubstituted phenyl, carboxy, or C₁ -C₃ alkoxycarbonyl. R₂ may be hydrogen, C₁ -C₆ alkyl, or substituted or unsubstituted phenyl. Preferably, R₂ is hydrogen, C₁ -C₃ alkyl, or substituted or unsubstituted phenyl. R₃ and R₄ may each be hydrogen, C₁ -C₆ alkyl or phenyl. Preferably, R₃ and R₄ are each hydrogen, C₁ -C₃ alkyl, or phenyl, R₅ and R₆ may each be hydrogen, C₁ -C₆ alkyl, phenyl, hydroxy, C₁ -C₆ alkoxy, or acetoxy. Preferably, R₅ and R₆ are each hydrogen, C₁ -C₃ alkyl, phenyl, hydroxy, C₁ -C₃ alkoxy, or acetoxy, R₇, R,₈, and R₁₀ may each be hydrogen, C₁ -C₆ alkyl, or phenyl, provided that when R₇ is phenyl, R₈ is hydrogen or C₁ -C₆ alkyl and when R₈ is phenyl R₇ is hydrogen or C₁ -C₆ alkyl. Preferably, R₇, R₈, and R₁₀ are each hydrogen, C₁ -C₃ alkyl, or phenyl. Most preferably, R₁, R₂ R₃, R₄, R₅, R₆, R₇, R₈, and R₁₀ are each hydrogen or methyl. R₁₁, R₁₂, R₁₃, R₁₄, R₁₅, and R₁₆ may each be hydrogen, C₁ -C₆ alkyl, C₁ -C₆ alkoxy, or phenyl, Preferably, R₁₁, R₁₂, R₁₃, R₁₄, R₁₅, and R₁₆ are each hydrogen, C₁ -C₃ alkyl, C₁ -C₃ alkoxy, or phenyl. Most preferably, R₁₁, R₁₂, R₁₃, R₁₄, R₁₅, and R₁₆ are each hydrogen, methyl, or methoxy.

In graphic formulae IIE and IIF, R₁₇ may be hydrogen, C₁ -C₆ alkyl, substituted or unsubstituted phenyl, or halogen. Preferably, R₁₇ is hydrogen, C₁ -C₃ alkyl, substituted or unsubstituted phenyl, or halogen. Most preferably, R₁₇ is hydrogen, methyl, or chloro. R₁₈ may be hydrogen, C₁ -C₆ alkyl, phenyl, carboxy, C₁ -C₆ alkoxy-carbonyl, or C₁ -C₆ haloalkoxycarbonyl. Preferably, R₈ is hydrogen, C₁ -C₃ alkyl, phenyl, carboxy, C₁ -C₃ alkoxycarbonyl, or C₁ -C₃ haloalkoxycarbonyl. R.sub.· and R₂₀ may each be hydrogen, C₁ -C₆ alkyl, or phenyl. Preferably, R.sub.· and R₂₀ are each hydrogen, C₁ -C₃ alkyl, or phenyl. Most preferably, R₁₈, R₁, and R₂₀ are each hydrogen or methyl. R₁₉ -R₂₀ the phenyl substituents may be C₁ -C₃ alkyl and the halogen or (halo) groups may be chloro or bromo.

In graphic formulae IA1, IA2, and IA3, B and B' may each be selected from the group consisting of (i) the substituted or unsubstituted aryl groups phenyl and naphthyl; (ii) the substituted or unsubstituted heterocyclic aromatic groups pyridyl, furyl, benzofuryl, thienyl, and benzothienyl; and (iii) B and B' taken together form the adamantyl group. The aryl and heterocyclic substituents of B and B' may each be selected from the group consisting of hydroxy, C₁ -C₃ alkyl, C₁ -C₅ haloalkyl, which includes mono-, di-, and trihalo substituents, C₁ -C₅ alkoxy, C₁ -C₅ alkoxy(C₁ -C₄)alkyl, C₁ -C₅ dialkylamino, acryloxy, methacryloxy, and halogen, said halogen or (halo) groups being fluoro, chloro, or bromo.

Preferably, B and B' are represented respectively by the following graphic formulae: ##STR7##

In graphic formulae IIIA and IIIB, Y₁ and Z₁ may each be selected from the group consisting of hydrogen, C₁ -C₅ alkyl, C₁ -C₅ alkoxy, fluoro, and chloro; Y₂ and Z₂ are each selected from the group consisting of C₁ -C₅ alkyl, C₁ -C₅ alkoxy, hydroxy, halogen, e.g., chloro, fluoro, and bromo, acryloxy, and methacryloxy, and a and b are each integers from 0 to 2. Most preferably, Y₁ and Z₁ are each hydrogen, C₁ -C₃ alkyl, C₁ -C₃ alkoxy, or fluoro, Y₂ and Z₂ are each C₁ -C₃ alkyl or C₁ -C₃ alkoxy, a is the integer 0 or 1, and b is an integer from 0 to 2.

The preferred naphthopyrans of the present invention are represented in the following graphic formula IB. In graphic formula IB, the A group represents formulae IIA through IID with X being an oxygen atom, formulae IIE and IIF. The A group is fused so that the oxygen atom of formulae IIA through IIF is attached to the number 8 carbon atom of the naphtho portion of the naphthopyran. ##STR8##

A still preferred dye may be described as naphthopyrans substituted at the 3 position of the pyran ring with (i) an aryl substituent and (ii) a phenyl substituent having a 5- or 6-member oxygen and/or nitrogen containing a heterocyclic ring fused at the number 3 and 4 carbon atoms of the phenyl substituent and with a nitrogen-containing hetero cyclic ring at the 6 position of the naphthyl portion of the naphthopyran compound. These compounds may be represented by the following graphic formula: ##STR9##

In graphic formula I, R₁ may be C₁ -C₁₀ alkyl, halogen, or the group, --O--L, wherein L is a C₁ -C₁₂ alkyl, e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, and dodecyl, said halogen being chloro, fluoro, or bromo, and a is the integer 0, 1 or 2. Preferably, R₁ is C₁ -C₅ alkyl, fluoro, bromo or the group, --O--L, wherein L is C₁ -C₄ alkyl and a is the integer 0 or 1. Most preferably, R₁ is C₁ -C₃ alkyl, fluorine or the group --O--L, wherein L is methyl, and a is the integer 0 or 1.

In graphic formula I, R₂ may be a saturated, unsubstituted or mono-or di-substituted nitrogen containing heterocyclic group selected from the following groups represented by graphic formulae IA through IG: wherein E and F in graphic formula IC, are each a nitrogen or carbon atom, provided that when E is nitrogen, F is carbon atom, and G in graphic formula ID, is a nitrogen, oxygen, or carbon atom and H is a nitrogen or carbon atom, provided that when H is nitrogen, G is a carbon atom. ##STR10##

Examples of R₂ groups include aziridino, azetidino, 1-pyrrolidyl, 1-pyrrolinyl, 1-imidazolin-1-yl, 2-imidazolin-1-yl, 2-pyrazolidyl, 3-pyrazolin-2-yl, morpholino, piperidino, piperazinyl, 4-methyl-l-piperazinyl, 1,4,5,6, -tetra-hydropyrimidinyl, 1-indolinyl, hexamethyleneimino, and heptamethyleneimmino. The substituents for R₂ can be C₁ -C₆ alkyl and/or C₁ -C₆ alkoxy. Preferably, R₂ is an unsubstituted or mono-substituted member of the group consisting of indolinyl, morpholino, and piperidino. More preferably, R₂ is morpholino.

B may be the substituted or unsubstituted aryl group, naphthyl or phenyl, said aryl substituents being C₁ -C₅ alkyl, halo(C₁ -C₅)alkyl, hydroxy, C₁ -C₅ alkoxy, C₁ -C₄ alkoxy(C₁ -C₄)alkyl, halogen, morpholino, piperidino, or R(R")N--, wherein R and R" are each hydrogen or C₁ -C₃ alkyl, said halogen (or halo) groups being fluoro or chloro. Preferably, B is represented by the following graphic formula II: ##STR11##

In graphic formula II, R₆ is hydrogen, C₁ -C₄ alkyl, C₁ -C₄ alkoxy, fluoro, or chloro and each R₇ is a C₁ -C₄ alkyl, C₁ -C₄ alkoxy, hydroxy, chloro, or fluoro and d is an integer from 0 to 2. Preferably, R₆ is hydrogen and R₇ is selected from the group consisting of fluoro, methyl and methoxy.

B' may be represented by one of the following graphic formulae III or IV: ##STR12##

In graphic formula III and IV, X is oxygen or nitrogen and Y is carbon or oxygen, provided that when X is nitrogen, Y is carbon; R₄ and R₅ are each hydrogen or C₁ -C₅ alkyl; each R₃ is a C₁ -C₃ alkyl, C₁ -C₅ alkoxy, hydroxy, or halogen, said halogen substituent being chloro, fluoro, or bromo, and c is an integer from 0 to 3, e.g., 0, 1, 2, or 3. Preferably, B' is represented by graphic formula III or IV, wherein X is oxygen; Y is carbon or oxygen; R₄ and R₅ are each hydrogen or C₁ -C₄ alkyl; each R₃ is a C₁ -C₄ alkyl, C₁ -C₄ alkoxy, hydroxy, or fluoro; and c is the integer 0, 1 or 2. Most preferably, B' is 2,3-dihydroxybenzofuran-5-yl, 2-methyldihydroxybenzofuran-5-yl, indoline-5-yl, 1,2,3,4-tetrahydroquinoline-6-yl, chroman-6-yl, or 1,3-benzodioxole-5-yl.

In graphic formula III, when R₄ and R₅ are H and when X is oxygen and Y is carbon and c is zero, the group is a 2,3-dihydrobenzo-furan-5-yl; when X is oxygen and Y is oxygen and c is zero, the group is 1,3-benzodioxole-5-yl; and when X is nitrogen and Y is carbon and c is zero, the group is indoline-5-yl. In graphic formula IV, when X is oxygen and Y is carbon, the unsubstituted group is a chroman-6-yl; when X is oxygen and Y is oxygen, the unsubstituted group is a 1,4-benzodioxan-6-yl; and when X is nitrogen and Y is carbon, the unsubstituted group is 1,2,3,4-tetrahydroquinoline-6-yl. For brevity, these groups will be referred to herein as fused heterocyclicphenyl groups.

The preferred naphthopyran dye is 3,3-diphenyl-3-H-naphtho[2,1-b]pyran represented by the formula ##STR13## where R₁ to R₆ denote hydrogen.

The spiroxazines suitable in the present invention are known: see for instance U.S. Pats. Nos. 3,562,172; 3,578,602; 4,215,010 and 4,342,668, all of which are incorporated by reference herein. Essentially, the spirooxazines suitable in the present invention may be described by the formula ##STR14## where: R₁ and R₂ independently represent a hydrogen or halogen (fluorine, chlorine or bromine) atom or a group chosen from C₁ -C₅ linear or branched alkyl, C₁ -C₅ perfluoro-alkyl, C₁ -C₅ alkoxy, nitro or cyano;

R₃ and R₄ independently represent C₁ -C₃ linear or branched alkyl, phenyl or benzyl groups; or R₃ and R₄ when considered jointly with the carbon atom to which they are linked form a C₅ -C₈ cycloalkyl group;

R₅ represents a C₁ -C₅ linear or branched alkyl, phenyl, benzyl or allyl group;

R₆ represents a hydrogen atom or a C₁ -C₅ linear or branched alkyl group or the group --NR₈ R₉ where R₈ is a C₁ -C₅ linear or branched alkyl, phenyl or benzyl group R₉ is hydrogen or has the same meaning as R₈, or R₈ and R₉ when considered jointly with the nitrogen atom to which they are linked form a cyclic structure comprising 5 to 12 members and possibly containing a further heteroatom chosen from oxygen and nitrogen; and R₇ represents a hydrogen or halogen (fluorine, chlorine or bromine) atom or a group chosen from: C₁ -C₅ linear or branched alkyl, C₁ -C₅ alkoxy, cyano, thio-ether and carboxylated ester with 1 to 3 carbon atoms in the ester portion, or represents an aromatic or heterocyclic condenses ring; X represents CH or N--.

In particular, the groups R₁ and R₂, when not hydrogen, can be linked in any of positions 4, 5, 6 and 7 of the indoline part of the molecule. In addition the group R₇, if not representing hydrogen or an aromatic or heterocyclic condensed ring, can be present in any of the positions 7', 8', 9' and 10' of the naphthalene part of the molecule.

In the preferred embodiment, photochromatic compounds corresponding to general formula (I) are used in which:

R₁ and R₂ independently represent a hydrogen atom or the methyl group;

R₃ and R₄ each represent the methyl group or jointly represent the cyclohexyl group;

R₅ represents the methyl group;

R₆ represents a hydrogen atom or the --NR₈ R₉ group where the groups R₈ and R₉ together with the nitrogen atom to which they are linked form a piperidyl, morpholyl, pyrrolidyl or hexamethyleneimino ring structure; and

R₇ represents a hydrogen atom; and

X represents CH.

Examples of preferred photochromatic compounds used according to the present invention are 1,3,3,4,5 or 1,3,3,5,6-pentamethyl spiro (indoline-2,3'-[3H]-naphtho-(2,1 -b)-(1,4)-oxazine); 1,3,3-trimethyl spiro (indoline-2,3'-[3H]-naphtho-2,1-b)-(1,4)-oxazine); 1,3,3-trimethyl spiro (indoline-6-(1-piperidyl)-2,3'-[3H]-naphtho-2,1-b)-(1,4)-oxazine; 1,3,3-trimethyl spiro (indoline-6'-(1-morpholyl)-2,3'-[3H]-naphtho-(2,1-b)-(1,4) -oxazine); 1,3,3,4,5- or 1,3,3,5,6-pentamethyl spiro (indoline-6'-(1-piperidyl)-2,3'-[3H]-naphtho-(2,1-b)-(1,4)-oxazine); and 1,3,3-trimethyl spiro (indoline-6'-(1-piperidyl)-9'-(methoxy)-2,3'-[3H]-naphtho-(2,1-b)-(1,4) -oxazine).

The spiropyrans useful for the purposes of the present invention, are photochromatic organic compounds, which can be defined by the following general formulae (II), (III), (IV) and (V): ##STR15##

In the preceding general formulae:

R₁₀ and R₁ represent alkyl or aryl groups;

R₁₂ represents an alkyl, aryl group or alkyl substituted group (such as hydroxyalkyl, halogenalkyl, carbalcoxyalkyl, alkoxyalkyl and amminoalkyl);

R₁₄ represents hydrogen or an alkyl, aryl or alkoxy

R₁₃ and R₁₅ represent hydrogen or mono- or poly-substitution groups, chosen among alkyl and substituted alkyl groups, or halogen, nitro or alkoxy.

Fulgides and fulgimides suitable in the context of the invention are known and have been described in the literature (see, for instance, Applied Photochromic Polymer Systems, Edited by C. B. McArdle, Blackie USA: Chapman & Hall, New York, 1992 pp. 80-120) incorporated by reference herein.

The matrices of the film (PCL/PC) and of the lens (PC) are sufficiently similar and there are no adhesion/delamination problems associated with the combination. Moreover, since the pressure of the molding operation conforms the film to the lens surface, bifocals and progressive lenses may be readily produced.

In making the lens of the invention, the well known "insert molding" practice may be used. Accordingly, the photochromic film is first placed in a mold and polycarbonate resin is then introduced in the mold. The introduction of the resin behind the film is preferably carried out by injection. The thickness of the film is preferably 5 mils.

The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.

EXAMPLES

Experimental

Compositions suitable for the preparation of the photochromic film of the invention were prepared and their photochromic properties determined.

In order to measure the darkening rate, the samples were exposed to UV radiation (Spectrolin long wavelength -365 nm- lamp) for ten minutes. The absorbancy at the peak maximum of the dye (424 nm for variacol Yellow L) was recorded at four seconds intervals of a ten minute period using a spectrophotometer (Perkin-Elmer Lambda 9 UV/Vis). Fading rate was measured in a similar manner after first removing the UV radiation source.

As UV radiation strikes the samples, which were tested, the incorporated photochromic dye begins to convert from a colorless to a colored state. More color develops as the exposure to UV radiation continues until the color intensity reaches a substantially constant plateau. Since the absorbance also increases as the photochromic dye converts from a colorless to a colored state, this value is a convenient measure of the rate at which the material darkens.

In the table below, T1/2 refers to the time (in seconds) to reverse to 50% absorbance. As the results shown in the table below demonstrate, the control composition which contained only polycarbonate and the dive of the invention proved to have slow rate in darkening and in fading; its; T1/2 values were 4 minutes and 5 seconds.

Articles molded of PCL are opaque and compositions containing only PCL and the dye of the invention are unsuitable for applications where transparency is a requirement.

The compositions, which were prepared and evaluated as tabulated below, contained as PCL, Tone 767 from Union Carbide, a resin characterized in that its weight average molecular weight is 50,000 g/mole). The dye used in the examples, at a level of 0.1 pphr, was 3,3-diphenyl-3-H-naphtho[2,1-b]pyran. The table shows the fade reversal rates.

                  TABLE 1                                                          ______________________________________                                                   Resinous components (wt %)                                           Example   Polycarbonate PCL     T.sub.1/2  (seconds)                           ______________________________________                                         1-1       100.sup.(1)   0       245                                            1-2       65.sup.(1)    35      18                                             1-3       75.sup.(1)    25      42                                             1-4       100.sup.(2)   0       >420                                           1-5       65.sup.(2)    35      29                                             ______________________________________                                          .sup.(1) the polycarbonate resin was Makrolon 2458 homopolycarbonate base      on bisphenol A, having a Melt Flow rate in accordance with ASTM D1238 of       about 20 g/10 min.                                                             .sup.(2) a copolycarbonate based on bisphenolA (65%) and                       2,2,4trimethylcyclohexyl 1,1 diphenol.                                   

The results show the effectiveness of the dyes of the invention to render the composition suitable as photochromic compositions.

The photochromic performance of a composition of the invention is further demonstrated by the results of its darkening and fading as tabulated below. The rates of darkening of compositions 1-1 and 1-2 above, upon exposure of test specimens to 424 nm light source are shown in Table 2. The test specimens were in the form of a PC substrate, 100 mils thick to which was laminated a 5 mil film of the noted composition.

                  TABLE 2                                                          ______________________________________                                                 absorbance upon exposure to UV radiation                                       Time (minutes)                                                         Composition                                                                            0        1        2      4      10                                     ______________________________________                                         1-1     0.0982   0.4239   0.4822 0.5313 0.5657                                 1-2     0.1687   0.6436   0.7409 0.7976 0.8508                                 ______________________________________                                    

The rate of fading upon removal of these specimens (Compositions 1-1 and 1-2) from the light source is shown in table 3.

                  TABLE 3                                                          ______________________________________                                                          Fade Time (seconds)                                           Composition      50%.sup.(1)                                                                            30%.sup.(2)                                           ______________________________________                                         1-1              245     46                                                    1-2              18      8                                                     ______________________________________                                          .sup.(1) Fade Time 50% refers to the time interval from the removal of th      fully darkened material from the light source and ending when the reversa      reached 50% of the maximum darkening.                                          .sup.(2) Fade Time 30% refers to the time interval from the removal of th      fully darkened material from the light source and ending when the reversa      reached 30% of the maximum darkening.                                    

In an additional, parallel set of experiments the photochromic compound used was 1,3-dihyro-1,3,3-trimethyl-spiro-2H-indole-2,3'-(3H) -naphth(2,1-b)-1,4-. The results were as follows:

                  TABLE 4                                                          ______________________________________                                                   Resinous components (wt %)                                           Example   Polycarbonate PCL     T.sub.1/2  (seconds)                           ______________________________________                                         4-1       100.sup.(1)   0       155                                            4-2       65.sup.(1)    35      15                                             4-3       75.sup.(1)    25      47                                             4-4       100.sup.(2)   0       300                                            4-5       65.sup.(2)    35      24                                             ______________________________________                                          .sup.(1) the polycarbonate resin was Makrolon 2458 homopolycarbonate base      on bisphenol A, having a Melt Flow rate in accordance with ASTM D1238 of       about 20 g/10 min.                                                             .sup.(2) a copolycarbonate based on bisphenolA (65%) and                       2,2,4trimethylcyclohexyl 1,1 diphenol.                                   

The photochromic performance of compositions of the invention is further demonstrated by the results of its darkening and fading as tabulated below. The rates of darkening of Compositions 4-1 and 4-2 above, upon exposure of test specimens (100 mils thick) to 424 nm light source are shown in Table 5.

                  TABLE 5                                                          ______________________________________                                                 absorbance upon exposure to UV radiation                                       Time (minutes)                                                         Composition                                                                            0        1        2      4      10                                     ______________________________________                                         4-1     0.0079   0.1813   0.2031 0.2174 0.2289                                 4-2     0.0759   0.2746   0.2842 0.2961 0.2863                                 ______________________________________                                    

The rate of fading upon removal of these specimens (Compositions 4-1 and 4-2) from the light source is shown in Table 6.

                  TABLE 6                                                          ______________________________________                                                          Fade Time (seconds)                                           Composition      50%.sup.(1)                                                                            30%.sup.(2)                                           ______________________________________                                         4-1              155     44                                                    4-2              15      6                                                     ______________________________________                                          .sup.(1) Fade Time 50% refers to the time interval from the removal of th      fully darkened material from the light source and ending when the reversa      reached 50% of the maximum darkening.                                          .sup.(2) Fade Time 30% refers to the time interval from the removal of th      fully darkened material from the light source and ending when the reversa      reached 30% of the maximum darkening.                                    

Films suitable in the context of the invention were evaluated as described below in Table 7. The polycarbonate used was Makrolon FCR 2458. Blue A refers to Variacrol Blue A; Yellow L refers to Variacrol Yellow L which is 3,3-diphenyl-3-H-naphtho[2,1 b]pyran.

The film, having a thickness of 5 mils was then inserted into the cavity of an injection mold and a 3 inch PC disk (100 mil thickness) was produced by conventional means. These disks were then compared to control samples, consisting of a PC film containing the same concentrations of photochromic dyes but without PCL, which were similarly molded onto a 3 inch disk.

The samples were irradiated with UV light to fully convert the photochromic dyes to the darken state. Full conversion to the darkened state was assured by measuring the darkening of the discs every minute until the transmission reached a steady state. Typically, the samples took about 10 minutes to reach equilibrium. The UV light source was then removed and the time required for the samples to reach 50% of their filly lightened state was determined and recorded as T1/2.

                  TABLE 7                                                          ______________________________________                                                      A        B        C      D                                        ______________________________________                                         PC, (%)      100      90       100    90                                       PCL (%)      --       10       --     10                                       Blue A (%)*  0.1      0.1      --     --                                       Yellow L (%)*                                                                               --       --       0.1    0.1                                      T.sub.1/2  (min)                                                                            1.9      1.6      3.8    1.9                                      ______________________________________                                    

As shown in the table, all the samples produced a photochromic behavior, i.e., they lightened and darkened in response to UV-radiation. However, the samples containing the PCL converted to the light form as much as twice as fast as controls.

The transition rate and the degree of darkness were strongly dependent on the concentration of dye in the film sample (i.e., the greater the dye concentration, the darker the sample after UV-radiation exposure).

Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. 

What is claimed is:
 1. An ophthalmic lens comprising(a) a substantially transparent substrate having a lenticular shape and, (b) at least one film adhering to at least one surface of said substrate,said film comprising a blend or copolymer of aromatic polycarbonate resin, PCL, and a positive amount of a photochromic dye sufficient to impart photochromicity to said lens.
 2. The lens of claim 1 wherein said film comprises(A) a resinous component selected from the group consisting of(i) a homogeneous blend of polycarbonate resin and polycarprolactone and (ii) a copoly(carbonate-lactone) block or random copolymer, and (B) a photochromic compound selected from a group consisting of spiropyrans, spiroxazines, fulgides and fulgimides, wherein said compound is present in an amount of 0.01 to 1.0 parts per hundred parts of weight of said (A).
 3. The lens of claim 1 wherein said film comprises(A) at least one resinous component selected from the group consisting of (i) a homogeneous blend of polycarbonate resin and polycaprolactone and (ii) a copoly(carbonatelactone) copolymer, and (B) at least one photochromic compound selected from a group consisting of benzopyrans, naphthopyrans, spirobenzopyrans, spironaphthopyrans, spirobenzoxazines, spironaphthoxazines, fulgides and fulgimides,wherein said compound is present in an amount of 0.01 to 1.0 parts per hundred parts of weight of said (A).
 4. The lens of claim 1 wherein said PCL is a block copolymer containing 1 to 50 mole % of units conforming to ##STR16##
 5. The lens of claim 1 wherein said PCL is a random copolymer containing 1 to 50 mole % of units conforming to
 6. The lens of claim 1 wherein said dye is a benzopyran.
 7. The lens of claim 1 wherein said dye is a naphthopyran.
 8. The lens of claim 1 wherein said dye is a spirobenzopyran.
 9. The lens of claim 1 wherein said dye is a spironaphthopyran.
 10. The lens of claim 1 wherein said dye is a spirobenzoxazine.
 11. The lens of claim 1 wherein said dye is a spironaphthoxazine.
 12. The lens of claim 1 wherein said dye is a fulgide.
 13. The lens of claim 1 wherein said dye is a fulgimide.
 14. The lens of claim 1 wherein said dye conforms to wherein R₁ is C₁ -C₁₀ alkyl, halogen, or the group, --O--L, wherein L is a C₁ -C₁₂ alkyl; a denotes 0,1 or 2; R₂ is a saturated nitrogen containing heterocyclic group; B is an aryl group and B' is selected from the group consisting of III and IV ##STR17## wherein X is oxygen or nitrogen and Y is carbon or oxygen, provided that when X is nitrogen, Y is carbon; and where R₄ and R₅ denote hydrogen or C₁ -C₅ alkyl; R₃ is a C₁ -C₅ alkyl, C₁ -C₅ alkoxy, hydroxy, or halogen atom, and c is an integer from 0 to
 3. 15. The lens of claim 1 wherein said dye conforms to ##STR18## where R₁ to R₆ denote hydrogen.
 16. The lens of claim 1 wherein said dye conforms to ##STR19##
 17. The lens of claim 1 wherein said dye is present in an amount of 0.03 to 0.5 parts per hundred parts by weight of the total of polycarbonate and PCL.
 18. An insert molding process for making an ophthalmic lens comprising placing the film of claim 1 in a mold and then introducing into said mold a resinous molding composition. 